Carpet construction



July 25,1944. J. E. G-RONENBERG 2,354,256

CARPET CONSTRUCTION Filed April 6, 1942 2 Sheets-Sheet 1 (IO/"27? E Grows/2561p y 1 4' J. E. GROQENBERG 2,354,256

CARPET CONSTRUCTION Filed April 6, 1942 2 Sheets-Sheet 2 Java/22 0i (75/57? 5' 611922672567 W Wf Patented July 25, 1944 UNITED STATES PATENTA OFFICE CARPET CONSTRUCTION John E. Gronenberg, Chicago, Ill. Application April 6, 1942, Serial No. 437,760

5 Claims.

The present invention relates generally to carpets and more particularly to the construction thereof.

One object of the invention is to provide a carpet which has certain advantages over standard or conventional carpets and not only is an improvement thereon but also has materially greater wearing properties.

Another object of the invention is to provide a carpet which comprises in addition to the regular pile tufts, auxiliary tufts in interspersed relation with the pile tufts. In general the auxiliary tufts are inserted into place through the bottom portion of the carpet after conventional fabrication of the carpet and, depending upon their arrangement, serve to ornament or strengthen the carpet as a whole or to replace or restore worn out portions in the carpet. They are U-shaped in conformation and it is contemplated that they be applied either in warpwise or weftwise rows, or in both types of rows. If the auxiliary tufts are applied in warpwise rows they extend around certain of the weft threads and straddle certain of the pile tufts. If the auxiliary tufts are arranged or disposed in weftwise rows they'extend around the threads constituting the warp, fit between the weft threads, and are disposed betweenyand at right angles to, the adjacent pile tufts.

A further object of the invention is to provide a carpet which is generally of new and improved construction and involves a simple method of manufacture or fabrication.

Other objects of the invention and the various advantages and characteristics of the present carpet construction will be apparent from a consideration of the following detailed description.

The invention consists in the several novel features which are hereinafter set forth and are more particularly defined by claims at the conclusion hereof. I

In the drawings which accompany and form a part of this specification or disclosure and in which like numerals of reference denote corresponding parts throughout the several views:

Figure 1 is a fragmentary plan view of a carpet embodying thev invention;

Figure 2- is an enlarged bottom view of that portion of the carpetwhich includes the auxiliary tufts, and illustrates the manner in which the warpwise auxiliary tufts straddle certain of the weft threads and pile tufts and the weftwise auxiliary tufts extend around or straddle certain of the warp threads; and

Figures 3, 4 and 5 are sections taken respectively on the lines 33, 44 and 5-5 of Figure 2.

The carpet which is shown in the drawings exemplifies the invention. It comprises a' plurality of warpwise auxiliary tufts 6 and a plurality of weftwise auxiliary tufts 'l and is of standard or conventional design except for such tufts. As hereinafter pointed out more in detail, the auxiliary tufts are arranged in interspersed relation with the standard pile tufts and serve to ornament or strengthen the carpet or to replace or restore worn out portions. The carpet of the drawings is of the Axminster type and represents merely one type of carpet to which the present invention is applicable. a series of laterally spaced parallel lower weft threads 8, a series of laterally spaced parallel intermediate weft threads 9," a series of laterally spaced parallel upper weft threads I 0, a series of laterally spaced substantially straight stuffer type warp threads ll between and at right angles to the lower and intermediate weft threads, a series of laterally spaced parallel substantially straight stuffer type warp threads l2 between and at right angles to the intermediate and upper weft threads 9 and I0, a series of laterally spaced parallel chain or binder type warp threads ill in juxtaposed relation with the stuifer type warp threads I I and I2, and U-shaped pile tufts It. The lower, intermediate and upper weft threads 8, 9 and I0 extend sidewise of the carpet and together constitute the weft. The threads ll, l2 and I3 constitute the warp of the carpet. ,The intermediate weft threads 9 are disposed directly over, and'are vertically aligned with, the lower weft threads 8, as shown in Figures 3 and 5. The upper weft threads I 0 are disposed above and between'the intermediate weft threads. The binder type warp threads l3 are looped alternately around the weft threads 8 and 9 and the upper weft threads l0 and serve as a medium for holding the weft threads in connected relation, as well understood in the art. Ordinarily the Weft threads are formed of jute or like stiff and thick material and the warp threads are formed of cotton, The pile tufts 14 are U-shaped and are positioned or arranged in straddled relation with the intermediate weft threads 9. They are formed of yarn and project upwards between the upper weft threads I0, as shown in Figure 3. As shOWn'in Figure 4, the tufts M are disposed between the threads ll, I2 and I3 constituting the warp of the carpet and extend in a warpwise direction.

The auxiliary tufts 6 are formed of yarn and are U-shaped so far as configuration is concerned.

It is machine made and comprises -or lap the side portions of the superposed standard pile tufts M. The central parts of the side portions of the tufts 6 straddle the intermediate Weft threads 9 and project upwards between the upper weft threads I0. It is contemplated that the auxiliary tufts 6 be arranged in rows and that the latter extend warpwise of the carpet.

The auxiliary tufts I are of thesame design and construction as the auxiliary tufts 6. They extend at right angles to the last mentioned tufts as well as the standard pile tuft l4. They are preferably arranged in rows which extend in the direction of the weft of the carpet. As shown in Figure 4 of the drawings the tufts 1 are arranged in straddled relation with the threads constituting the Warp of the carpet, i. e., the threads H, I 2 and i3. The curved or lower portions of the tufts I straddle the portions of the threads Ii that are between, the lower weft threads 8. The central parts of the side portions of the tufts 1 lap or straddle the stuffer type warp threads 12 and project upwardsthrough the spaces between the intermediate Weft threads 9 and the upper weft threads Hi. The auxiliary tufts 1 are applied in the same manner as the auxiliary tufts 6.

It is contemplated that theauxiliary tufts 6 and i will be materially longer' than the standard pile tufts I4 when inserted intoplace and that the upper ends thereof will be trimmed to a height corresponding to the upper ends of the standard pile tufts. If th auxiliary tufts are used for the purpose of ornamentation they will be formed of different material or a difierent color than the standard pile tufts and will be applied according to any desired design or pattern. If the auxiliary tuftsare desired for re-, enforcing purposes they will be formed of the sam material and the same color as the standard pile tufts I4. Regardless of whether the auxiliary tufts are used for ornamentation or for reenforcement they serve materially to strengthen or reenforce the carpet and give the latter an extremely long life. If desired the auxiliary tufts may be used to restore any worn out spots or areas in the carpet. Such tufts may also be used to reenforce or increase the pile structure of any particular portion of the carpet which is subject to excessive wear or use. When the auxiliary tufts are employed in connection with portions of the carpet that are subject to excessive use Or wear they effectively and efficiently prevent crushing of the pile and in this way eliminate Wear. The auxiliary tufts B serve not only for pil ornamentation, reenforcement or restoration, but also as a medium for assisting the chain or binder type warp threads l3 1n holding the lower and intermediate weft threads 8 and 9 in place. They also serve to hold in place the standard pile tufts that they straddle. The auxiliary tufts I serve effectively and eificiently to lock together against lateral displacement the threads II, I! and I3 constituting the warp and hence have a second or auxiliary function. The bottom portions of the auxiliary tufts 6 project beneath the lower weft threads 8 and hence provide an irregular bottom surface for the carpet whereby skidding or slipping of the carpet is eliminated.

Whereas the invention has been described in connection with a carpet of the Axminster type it is to be understood it may be employed or used in connection with other types of carpet, such as Wilton, Brussels, velvet, etc. It is also to be understood that the invention is not to be restricted to the details set forth since thes may be modified within the scope of the appended claims without departing from the spirit and scope of the invention.

Having thus described the invention what I claim as new and desire to secure by Letters Patent is:

1. As a new article of manufacture, a carpet having rows of standard U-shaped pile tufts and in addition auxiliary U-shaped tufts arranged in parallel and straddled relation with certain of the standard pile tufts and additional auxiliary U-shaped tufts arranged in interspersed relation with, and at right angles to, the standard pile tufts.

2. As a new article of manufacture, a carpet embodying a base structure in th form of a series of laterally spaced parallel weft threads and warp thread in woven relation with said weft threads and a pile structure in the form of U- shaped tufts extending around and projecting upwardly from certain of the weft threads, and also embodying auxiliary U-shaped tufts extending at right angles to, and in interspersed relation with, the standard pile tufts and looped around portions of the warp threads.

3. As a new article of manufacture, a carpet embodying a base structure in the form of a series of laterally spaced parallel weft threads and warp threads in woven relation with said weft threads and a pile structure in the form of standard U-shaped tufts extending around and projecting upwardly from certain of the weft threads, and also embodying auxiliary warpwise extending U-shaped tufts arranged in parallel and straddled relation with certain of the standard pile tufts and extending upwards between the weft threads, and weftwise extending auxiliary U-shaped tufts extending at right angles to, and in interspersed relation with the standard pile tufts and looped around portions of the warp threads.

4. That improvement in the carpet art which comprises inserting through the under side of a conventional pile type carpet, U-shaped auxiliary A tufts in such manner that they are in parallel relation with and straddle certain of the standard pile tufts.

5. That improvement in the carpet art which comprises inserting through the under side of a conventional machine made pile type carpet, U- shaped auxiliary tufts in such manner that they extend at right angles to, and are interspersed with, certain of the standard pile tufts and are looped around portions of the warp threads.

JOHN E. GRONENBERG. 

